Liquid only lance injector

ABSTRACT

A lance injector assembly for an exhaust component includes: a shaft configured to extend into an exhaust conduit of the exhaust component, the shaft being hollow so as to define a channel therethrough, wherein an opening is defined in a wall of the shaft proximate to a second end of the shaft that is opposite the first end; a cap coupled to a first end of the shaft; and a supply line disposed within the channel defined by the shaft, wherein a nozzle is disposed at a downstream end of the supply line, the nozzle being fluidly coupled to the shaft around the opening such that reductant is able to flow from the nozzle through the opening and into an exhaust gas flowing through the exhaust conduit. Air is present in the space between the supply line and the wall of the shaft, the air inhibiting heat transfer to the supply line.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 16/909,010, filed Jun. 23, 2020, which claims the benefit of U.S.Provisional Application No. 62/867,086, filed Jun. 26, 2019. Thesedisclosures are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The present application relates generally to systems and methods forreductant delivery in aftertreatment systems for internal combustionengines.

BACKGROUND

For internal combustion engines, such as diesel engines, nitrogen oxide(NO_(x)) compounds may be emitted in the engine exhaust. It may bedesirable to reduce NO_(x) emissions to, for example, comply withenvironmental regulations. To reduce NO_(x) emissions, a reductant maybe dosed into the exhaust by a dosing system. The reductant facilitatesconversion of a portion of the exhaust into non-NO_(x) emissions, suchas nitrogen (N₂), carbon dioxide (CO₂), and water (H₂O), therebyreducing NO_(x) emissions.

SUMMARY

In one embodiment, a lance injector assembly for an exhaust componentincludes a reductant source and a lance. The lance injector assemblyincludes a lance and a poppet valve. The lance includes a lance housing,a supply passage fluidly coupled to a reductant source and terminatingat a nozzle orifice, and a return passage fluidly coupled to thereductant source. The poppet valve is positioned downstream of thenozzle orifice and includes a poppet movable between a closed positionand an open position. When operating in a recirculation mode, the poppetis in the closed position to permit a full portion of reductant suppliedto the lance from the reductant source to return to the reductantsource. When operating in an injection mode, the poppet is in the openposition to permit a first portion of reductant to flow from the nozzleorifice and a second portion of reductant to return to the reductantsource.

In some embodiments, the lance includes an insulating layer surroundingthe supply passage and the return passage. In other embodiments, theinsulating layer includes a vacuum insulation material.

In some embodiments, the lance housing includes a first housing portionand a second housing portion. The first housing portion is orientedperpendicularly to the second housing portion.

In some embodiments, the supply passage is coaxially aligned with thereturn passage. In other embodiments, the return passage at leastpartially surrounds the supply passage.

In some embodiments, the lance injector assembly includes a supply pumpconfigured to increase a pressure of reductant in the supply passagewhen the lance injector assembly is operating in the injection mode. Inother embodiments, the supply pump includes a voice coil or solenoid. Infurther embodiments, the lance injector assembly includes a controllerprogrammed to control the supply pump such that the pressure ofreductant in the supply passage when the lance injector assembly isoperating in the injection mode is within a range of 25 to 35 bar. Instill further embodiments, the lance injector assembly includes acontroller programmed to control the supply pump such that the pressureof reductant in the supply passage when the lance injector assembly isoperating in the recirculation mode is within a range of 9 to 11 bar.

In some embodiments, the lance injector does not use air as a transportmechanism for a supply of reductant.

In another embodiment, a lance injector assembly for an exhaustcomponent is provided. The lance injector assembly includes an exhaustconduit and a shaft configured to extend into the exhaust conduit anddispense reductant from a hydraulically-actuated valve. The lanceinjector assembly further includes an actuator configured to operate thehydraulically-actuated valve, and a mounting system configured to couplethe actuator and the shaft to the exhaust conduit. The mounting systemprevents the actuator from directly contacting the exhaust conduit.

In some embodiments, the lance injector assembly includes multiplecooling lines located within the shaft. The cooling lines are configuredto circulate a coolant. In other embodiments, the coolant is at leastone of reductant, an engine fluid, a transmission fluid, air (or anyother onboard gas), and/or refrigerant as a cooling medium.

In some embodiments, a length of the shaft is within a range of 2.5inches to 6.5 inches.

In some embodiments, the hydraulically-actuated valve comprises a springoperated valve. In other embodiments, the spring operated valvecomprises a spring configured to exert a preload force against a valvemember. The valve member is configured to block reductant from flowingthrough a nozzle orifice.

In some embodiments, the lance injector does not use air as a transportmechanism for a supply of reductant.

In some embodiments, the hydraulically-actuated valve is configured tobe operated by controlling a pressure of the reductant.

In some embodiments, the hydraulically-actuated valve is configured tobe operated by mechanical actuation of a shaft component.

In some embodiments, a lance injector assembly for an exhaust componentcomprises: a shaft configured to extend into an exhaust conduit of theexhaust component, the shaft being hollow so as to define a channeltherethrough, wherein an opening is defined in a wall of the shaftproximate to a second end of the shaft that is opposite the first end; acap coupled to a first end of the shaft; and a supply line disposedwithin the channel defined by the shaft, wherein a nozzle is disposed ata downstream end of the supply line, the nozzle being fluidly coupled tothe shaft around the opening such that reductant is able to flow fromthe nozzle through the opening and into an exhaust gas flowing throughthe exhaust conduit, wherein air is present in the space between thesupply line and the wall of the shaft, the air inhibiting heat transferto the supply line.

In some embodiments, the lance injector assembly further comprises: anadapter coupled to the downstream end of the supply line, the adapterdefining an aperture therethrough, the nozzle being disposed on ordefined by a downstream end of the aperture, wherein the aperture has afirst diameter proximate to the supply line and a second diametersmaller than the first diameter distal from the supply line such thatthe aperture tapers inwardly from the supply line towards the nozzle.

In some embodiment, the cap comprises: an annular portion; a central hubdisposed circumferentially inwards of the annular portion around alongitudinal axis of the cap; and a plurality of radial ribs extendingfrom an outer periphery of the central hub to an inner periphery of theannular portion and coupled to the annular portion such that gaps aredefined between adjacent ribs of the plurality of ribs, wherein thesupply line extends through the central hub into the shaft. In someembodiments, the cap further comprises: an insulating bushing disposedin the central hub around a portion of the supply line that us disposedin the central hub, the insulating bush configured to inhibit heattransfer to the supply line from the central hub.

In some embodiments, the lance injector assembly further comprises: aninsulating layer disposed around the shaft. In some embodiments, thelance injector assembly further comprises: an adapter protrudingoutwardly from the opening, the nozzle being included in the adapter.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features,aspects, and advantages of the disclosure will become apparent from thedescription, the drawings, and the claims, in which:

FIG. 1 is a block schematic diagram of an example aftertreatment system;

FIG. 2 is a block schematic diagram of a liquid only lance injectorassembly for use in an aftertreatment system, such as the exampleaftertreatment system shown in FIG. 1;

FIG. 3 is a cross-sectional view of a liquid only lance in a closedposition for use in an injector assembly, such as the example injectorassembly shown in FIG. 2;

FIG. 4 is a cross-sectional view of a liquid only lance in an openposition for use in an injector assembly, such as the example injectorassembly shown in FIG. 2;

FIG. 5 is a perspective view of another example liquid only lanceinjector assembly for use in an aftertreatment system, such as theexample aftertreatment system shown in FIG. 1;

FIG. 6 is a cross-sectional view of the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 7 is another cross-sectional view of the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 8 is another cross-sectional view of the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 9 is another cross-sectional view of the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 10 is another cross-sectional view of the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 11 is a cross-sectional view of a hydraulic actuator assembly for aliquid only lance, such as the example liquid only lance injectorassembly shown in FIG. 5;

FIG. 12 is a cross-sectional view of another hydraulic actuator assemblyfor a liquid only lance, such as the example liquid only lance injectorassembly shown in FIG. 5;

FIG. 13 is a perspective view of a full length direct needle lift nozzleassembly for a liquid only lance, such as the example liquid only lanceinjector assembly shown in FIG. 5;

FIG. 14 is a cross-sectional view of the full length direct needle liftnozzle assembly shown in FIG. 13;

FIG. 15 is a perspective view of a shortened length direct needle liftnozzle assembly for a liquid only lance, such as the example liquid onlylance injector assembly shown in FIG. 5;

FIG. 16 is a cross-sectional view of the shortened length direct needlelift nozzle assembly shown in FIG. 15;

FIG. 17 is a cross-sectional view of a direct actuation nozzle assemblyfor a liquid only lance, such as the example liquid only lance injectorassembly shown in FIG. 5;

FIG. 18 is a cross-sectional view of a gate valve actuation assembly ina closed position for a liquid only lance, such as the example liquidonly lance injector assembly shown in FIG. 5;

FIG. 19 is a cross-sectional view of the gate valve actuation assemblyof FIG. 19 in an open position;

FIG. 20 is a cross-sectional view of a mechanical actuator assembly fora liquid only lance, such as the example liquid only lance injectorassembly shown in FIG. 5.

FIG. 21 is a side view of a liquid only lance injector assembly,according to an embodiment.

FIG. 22 is a bottom, side view of a portion of the liquid only lanceinjector assembly of FIG. 21 indicated by the arrow A in FIG. 21 with alower portion of a shaft of the lance injector assembly removed.

FIG. 23 is a side perspective view of a liquid only lance injectorassembly, according to an embodiment.

FIG. 24 is a side view of a portion of the liquid only lance injectorassembly of FIG. 23 indicated by the arrow B in FIG. 23.

FIG. 25 is a schematic illustration of a portion of lance injectorassembly showing an adapter and a nozzle included in the liquid onlylance injector assembly of FIG. 23.

FIG. 26 is a side view of a liquid only lance injector assembly,according to an embodiment.

FIG. 27 is a schematic illustration of a portion of lance injectorassembly showing an adapter and a nozzle included in the liquid onlylance injector assembly of FIG. 26.

FIG. 28 is a top, side perspective view of a liquid only lance injectorassembly, according to an embodiment.

FIG. 29 is a top, side perspective view of a liquid only lance injectorassembly, according to another embodiment.

FIG. 30 is a side perspective view of a liquid only lance injectorassembly, according to still another embodiment.

FIG. 31 is another side view of the liquid only lance injector assemblyof FIG. 30 with an insulation layer disposed thereon.

FIG. 32 is a top view of a cap included in the liquid only lanceinjector assembly of FIG. 30.

It will be recognized that some or all of the figures are schematicrepresentations for purposes of illustration. The figures are providedfor the purpose of illustrating one or more implementations with theexplicit understanding that they will not be used to limit the scope orthe meaning of the claims.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various conceptsrelated to, and implementations of, methods, apparatuses, and systemsfor delivering reductant through conduits within an aftertreatmentsystem of an internal combustion engine system. The various conceptsintroduced above and discussed in greater detail below may beimplemented in any of numerous ways, as the described concepts are notlimited to any particular manner of implementation. Examples of specificimplementations and applications are provided primarily for illustrativepurposes.

I. Overview

Internal combustion engines (e.g., diesel internal combustion engines,etc.) produce exhaust gases that are often treated by a doser within anaftertreatment system. Dosers typically treat exhaust gases using areductant. The reductant is typically provided from the doser into adosing lance which distributes (e.g., doses, injects) the reductant intoan exhaust stream within an exhaust component.

Centerline-style lance injectors that extend to the approximatecenterline of an exhaust pipe provide several advantages over tangentialor side mount dosers, which may incur problems with impingement ordeposit formation inside the mixer and low inherent uniformity in thereductant spray. Many centerline-style dosing systems utilize an airpump to propel the reductant from the dosing lance into the exhauststream. The air pump may draw air from an air source (e.g., air intake)and provide air to a dosing lance that is configured to mix the air andreductant into an air-reductant mixture. However, the inclusion of anair pump for this purpose may add unnecessary cost and complexity to theaftertreatment system. In some vehicles, the addition of an air supplysystem may be impossible.

Implementations described herein relate to an exhaust aftertreatmentsystem that includes a liquid only (i.e., airless) lance injector.Existing liquid only lance injector systems utilize tangential or sidemount dosers to protect the doser actuation valve from the high heatconditions experienced within the exhaust stream, which may includetemperatures up to 650° C. The centerline-style doser embodimentsdescribed herein locate any sensitive actuator components outside of theflow the exhaust gas and use a variety of hydraulic actuation methodswithin the lance assembly itself to control the flow of reductant fromthe doser. In addition, the embodiments described herein utilize avarious insulating and cooling methods to protect the lance and thereductant supply from deposit formation.

II. Overview of Aftertreatment System

FIG. 1 depicts an aftertreatment system 100 having an example reductantdelivery system 102 for an exhaust system 104. The aftertreatment system100 also includes a particulate filter (e.g., a diesel particulatefilter (DPF) 106, a decomposition chamber 108 (e.g., reactor, reactorpipe, etc.), a SCR catalyst 110, and a sensor 112.

The DPF 106 is configured to (e.g., structured to, able to, etc.) removeparticulate matter, such as soot, from exhaust gas flowing in theexhaust system 104. The DPF 106 includes an inlet, where the exhaust gasis received, and an outlet, where the exhaust gas exits after havingparticulate matter substantially filtered from the exhaust gas and/orconverting the particulate matter into carbon dioxide. In someimplementations, the DPF 106 may be omitted.

The decomposition chamber 108 is configured to convert a reductant intoammonia. The reductant may be, for example, urea, diesel exhaust fluid(DEF), Adblue®, an urea water solution (UWS), an aqueous urea solution(e.g., AUS32, etc.), and other similar fluids. The decomposition chamber108 includes a reductant delivery system 102 having a doser or dosingmodule 114 configured to dose the reductant into the decompositionchamber 108 (e.g., via an injector). In some implementations, thereductant is injected upstream of the SCR catalyst 110. The reductantdroplets then undergo the processes of evaporation, thermolysis, andhydrolysis to form gaseous ammonia within the exhaust system 104. Thedecomposition chamber 108 includes an inlet in fluid communication withthe DPF 106 to receive the exhaust gas containing NO_(x) emissions andan outlet for the exhaust gas, NO_(x) emissions, ammonia, and/orreductant to flow to the SCR catalyst 110.

The decomposition chamber 108 includes the dosing module 114 mounted tothe decomposition chamber 108 such that the dosing module 114 may dosethe reductant into the exhaust gases flowing in the exhaust system 104.The dosing module 114 may include an insulator 116 interposed between aportion of the dosing module 114 and the portion of the decompositionchamber 108 on which the dosing module 114 is mounted. The dosing module114 is fluidly coupled to (e.g., fluidly configured to communicate with,etc.) a reductant source 118. The reductant source 118 may includemultiple reductant sources 118. The reductant source 118 may be, forexample, a diesel exhaust fluid tank containing Adblue®.

A supply unit or reductant pump 120 is used to pressurize the reductantfrom the reductant source 118 for delivery to the dosing module 114. Insome embodiments, the reductant pump 120 is pressure controlled (e.g.,controlled to obtain a target pressure, etc.). The reductant pump 120includes a filter 122. The filter 122 filters (e.g., strains, etc.) thereductant prior to the reductant being provided to internal components(e.g., pistons, vanes, etc.) of the reductant pump 120. For example, thefilter 122 may inhibit or prevent the transmission of solids (e.g.,solidified reductant, contaminants, etc.) to the internal components ofthe reductant pump 120. In this way, the filter 122 may facilitateprolonged desirable operation of the reductant pump 120. In someembodiments, the reductant pump 120 is coupled to a chassis of a vehicle(e.g., maritime vehicle, boat, shipping boat, barge, container ship,terrestrial vehicle, construction vehicle, truck, etc.) associated withthe aftertreatment system 100.

The dosing module 114 and reductant pump 120 are also electrically orcommunicatively coupled to a controller 124. The controller 124 isconfigured to control the dosing module 114 to dose the reductant intothe decomposition chamber 108. The controller 124 may also be configuredto control the reductant pump 120. The controller 124 may include amicroprocessor, an application-specific integrated circuit (ASIC), afield-programmable gate array (FPGA), etc., or combinations thereof. Thecontroller 124 may include memory, which may include, but is not limitedto, electronic, optical, magnetic, or any other storage or transmissiondevice capable of providing a processor, ASIC, FPGA, etc. with programinstructions. This memory may include a memory chip, ElectricallyErasable Programmable Read-Only Memory (EEPROM), Erasable ProgrammableRead Only Memory (EPROM), flash memory, or any other suitable memoryfrom which the associated controller 124 can read instructions. Theinstructions may include code from any suitable programming language.

The SCR catalyst 110 is configured to assist in the reduction of NO_(x)emissions by accelerating a NO_(x) reduction process between the ammoniaand the NO_(x) of the exhaust gas into diatomic nitrogen, water, and/orcarbon dioxide. The SCR catalyst 110 includes an inlet in fluidcommunication with the decomposition chamber 108 from which exhaust gasand reductant are received and an outlet in fluid communication with anend of the exhaust system 104.

The exhaust system 104 may further include an oxidation catalyst (e.g.,a diesel oxidation catalyst (DOC)) in fluid communication with theexhaust system 104 (e.g., downstream of the SCR catalyst 110 or upstreamof the DPF 106) to oxidize hydrocarbons and carbon monoxide in theexhaust gas.

In some implementations, the DPF 106 may be positioned downstream of thedecomposition chamber 108. For instance, the DPF 106 and the SCRcatalyst 110 may be combined into a single unit. In someimplementations, the dosing module 114 may instead be positioneddownstream of a turbocharger or upstream of a turbocharger.

The sensor 112 may be coupled to the exhaust system 104 to detect acondition of the exhaust gas flowing through the exhaust system 104. Insome implementations, the sensor 112 may have a portion disposed withinthe exhaust system 104; for example, a tip of the sensor 112 may extendinto a portion of the exhaust system 104. In other implementations, thesensor 112 may receive exhaust gas through another conduit, such as oneor more sample pipes extending from the exhaust system 104. While thesensor 112 is depicted as positioned downstream of the SCR catalyst 110,it should be understood that the sensor 112 may be positioned at anyother position of the exhaust system 104, including upstream of the DPF106, within the DPF 106, between the DPF 106 and the decompositionchamber 108, within the decomposition chamber 108, between thedecomposition chamber 108 and the SCR catalyst 110, within the SCRcatalyst 110, or downstream of the SCR catalyst 110. In addition, two ormore sensors 112 may be utilized for detecting a condition of theexhaust gas, such as two, three, four, five, or six sensors 112 witheach sensor 112 located at one of the aforementioned positions of theexhaust system 104.

The dosing module 114 includes a dosing lance assembly 126. The dosinglance assembly 126 includes a delivery conduit (e.g., delivery pipe,delivery hose, etc.). The delivery conduit is fluidly coupled to thereductant pump 120. The dosing lance assembly 126 includes at least oneinjector 128. The injector 128 is configured to dose the reductant intothe exhaust gases (e.g., within the decomposition chamber 108, etc.).While not shown, it is understood that the dosing module 114 may includea plurality of injectors 128.

III. Liquid Only Lance Assembly

FIG. 2 illustrates an example liquid only aftertreatment system 200. Theliquid only aftertreatment system 200 is included in an internalcombustion engine system. The system receives and treats exhaust gagesproduced by the internal combustion engine.

The aftertreatment system 200 includes a dosing assembly 202, analogousto the dosing module 114 in FIG. 1, and an exhaust system 204, analogousto the exhaust system 104 in FIG. 1. The dosing assembly 202 isconfigured to selectively dose reductant into an exhaust conduit 206,such as the decomposition chamber 108 in FIG. 1, of the aftertreatmentsystem. In various embodiments, the dosing assembly 202 is mounted on(e.g., coupled to, attached to) the exhaust conduit 206. For example,the dosing assembly 202 may extend through an aperture in the exhaustconduit 206 and be fastened to the exhaust conduit 206 about theaperture. The exhaust conduit 206 is configured to receive exhaust gasesfrom the internal combustion engine (e.g., from an exhaust manifold,from a DPF, from an upstream component of the aftertreatment system) andprovide treated exhaust gases to a downstream component of theaftertreatment system (e.g., an SCR catalyst).

The dosing assembly 202 is supplied with reductant from a reductant pump208, analogous to the reductant pump 120. The reductant pump 208 may belocated within a reductant tank 210, as depicted in FIG. 2, or remotelymounted from the reductant tank 210. The reductant tank 210 isconfigured to store reductant therein. In various embodiments, thereductant pump 208 may be a bladder pump, a peristaltic pump, or anyother suitable type of pump. The reductant pump 208 may include aninternal filter configured to filter or strain the reductant to removecontaminants. In some embodiments, the pump 208 operates on thereductant before the reductant passes through the filter. In otherembodiments, the pump 208 operates on the reductant after the reductantpasses through the filter. In various embodiments, the internal filtermay comprise a cellulose material, a polymer material, a mesh, or anyother media suitable for performing filtering activities.

The reductant pump 208 may further include a heater configured to heatthe reductant in the filter. For example, the heater may be configuredto maintain the temperature of the reductant in the filter above thefreezing temperature of the reductant. In some embodiments, thereductant pump 208 includes reverse flow capabilities that may aid inpurging or extracting reductant from the aftertreatment system 200 inthe event of a shutdown of the aftertreatment system 200 or wheneverelse system purging is required.

The reductant pump 208 is fluidly coupled to the dosing assembly 202using a supply line 212. The supply line 212 may comprise a hose, atube, a channel, or the like. The dosing assembly 202 is shown toinclude a supply pump 216, and a lance injector assembly 218. The lanceinjector assembly 218 may be configured to operate in a recirculationmode and an injection mode, described in further detail below. In therecirculation mode, no reductant is discharged from the lance injectorassembly 218 and all reductant supplied through the supply line 212 isreturned to the reductant tank 210 via a return line 214. The returnline 214 may comprise a hose, a tube, a channel, or the like. In theinjection mode, a first portion of reductant discharged from lanceinjector assembly 218 and a second portion of reductant is returned tothe reductant tank 210 via the return line 214.

The supply pump 216 may act to increase the pressure within the supplyline 212. For example, when the supply pump 216 is not activated, thepressure of the reductant within the supply line 212 may range fromapproximately (i.e., ±10%) 5 bar (i.e., 73 psi) to 11 bar (i.e., 160psi). When the supply pump 216 is activated, the pressure of thereductant within the supply line 212 may be increased to a high valueranging from 11.1 bar (i.e., 161 psi) to 100 bar (i.e., 1,450 psi). Thepressure increase in the supply line 212 may be sufficient to actuate ahydraulic actuator in the lance injector assembly 218 and permit a flowof reductant to exit the lance injector assembly 218. In this way, theinjection rate of the flow or reductant from the lance injector assembly218 may be calibrated to the operation of the supply pump 216.

The supply pump 216 is electrically or communicatively coupled to acontroller (not shown), analogous to the controller 124 in FIG. 1. Thecontroller is programmed to control the supply pump 216. The controllermay include a microprocessor, an application-specific integrated circuit(ASIC), a field-programmable gate array (FPGA), etc., or combinationsthereof. The controller may include memory, which may include, but isnot limited to, electronic, optical, magnetic, or any other storage ortransmission device capable of providing a processor, ASIC, FPGA, etc.with program instructions. This memory may include a memory chip,Electrically Erasable Programmable Read-Only Memory (EEPROM), ErasableProgrammable Read Only Memory (EPROM), flash memory, or any othersuitable memory from which the associated controller can readinstructions. The instructions may include code from any suitableprogramming language.

In some embodiments, the supply pump 216 includes a solenoid or a voicecoil actuator. The solenoid or voice coil actuator may be configuredsuch that the nominal position of the solenoid or voice coil is open topermit the flow of reductant for recirculation purposes and to permitpurging of reductant from the dosing assembly 202 in the absence of asignal or power provided to the solenoid or voice coil. In someembodiments, the supply pump 216 additionally includes pressure andtemperature sensors configured to detect the pressure and temperature ofthe reductant within the supply line 212. For example, when thetemperature sensors detect freezing conditions in the supply line 212,the supply pump 216 may act to evacuate the dosing assembly 202 to avoiddamage caused by reductant expansion. Similarly, the supply pump 216 mayact to evacuate the dosing assembly 202 when temperature sensors detecta hot shutdown, because overheating the reductant can result in theformation of solid deposits that may clog the dosing assembly 202.

The lance injector assembly 218 is shown to extend into the exhaustconduit 206 such that the outlet of the lance injector assembly 218 ispositioned at the approximate centerline of the exhaust conduit 206.Centerline injectors provide several advantages over other types ofinjectors including the prevention of reductant deposits andimpingement. Delivery conduit or lance injector assembly 218 is shown toinclude a lance housing having a substantially L-shaped geometry. Inother words, a first portion of the housing of the lance injectorassembly 218 may be oriented substantially perpendicularly to a secondportion of the housing of the lance injector assembly 218. Thisorientation may permit gravity to aid in draining reductant from thelance injector assembly 218 upon shutdown of the aftertreatment system200. In other embodiments, different geometries for the housing of thelance injector assembly 218 may be utilized.

FIGS. 3 and 4 depict the lance injector assembly 218 in the reductantrecirculation and injection modes, respectively. Reductant may besupplied to the lance injector assembly 218 using a supply passage 302that is fluidly coupled to the supply line 212. The supply passage 302may be surrounded by one or more return passages 304 that are fluidlycoupled to the return line 214. The flow of reductant through the returnpassages 304 may cool the supply passage 302 and prevent deposits fromforming in the supply passage 302. In some embodiments, the supplypassage 302 may be situated in a coaxial orientation with a singlereturn passage 304 that fully surrounds and permits the flow ofreductant around the entire supply passage 302. In other embodiments,one or more discrete return passages 304 may be situated around thesupply passage 302. The supply passage 302 and the return passage 304may be surrounded by an insulating layer 306 that slows or prevents thetransfer of heat from the exhaust flow to the supply passage 302. Insome embodiments, the insulating layer 306 is a vacuum insulator,meaning that the layer includes at least one space either substantiallyor completely evacuated of air. In other embodiments, the insulatinglayer 306 may be fabricated from any other suitable insulating material.

A poppet valve assembly 308 may be positioned downstream of a supplyflow 318 of reductant traveling through the supply passage 302. Bypositioning the poppet valve assembly 308 downstream of the supply flow318, crystallization of the reductant and a risk of clogging the supplypassage 302 is minimized. The poppet valve assembly 308 includes anouter shell 310 and a poppet 312 that is coupled to a spring 314. Eachof the components of the poppet valve assembly 308 may be fabricatedfrom one or more high temperature materials, such as 300 or 400 seriesstainless steel, austenitic nickel-chromium-based superalloys (Inconel),or nickel-based alloys. The shape of the outer shell 310 may beaerodynamically optimized (i.e., formed with a geometry similar to thenose cone of an airplane) to prevent exhaust recirculation around thelance injector assembly 218, which could result in the formation ofreductant deposits.

When the lance injector assembly 218 is operating in the recirculationmode, as depicted in FIG. 3, the poppet 312 is in a closed position. Inthe closed position, the poppet 312 is seated against one or more nozzleopenings 316 to prevent the supply flow 318 of reductant from exitingthe lance injector assembly 218. Instead, the entire supply flow 318 ofreductant is returned to the return line 214 as a return flow 320passing through the one or more return passages 304. A preload forceholding the poppet 312 in the seated position may be provided by spring314. In other embodiments, the preload force is provided by anothercomponent or method.

When the lance injector assembly 218 is operating in the injection mode,as depicted in FIG. 4, the poppet 312 is in an open position. Forexample, the lance injector assembly 218 may operate in the injectionmode when an exhaust flow 402 is passing through the exhaust system inwhich the lance injector assembly 218 is mounted. The poppet 312 maytransition from the closed position of the recirculation mode to theopen position of the injection mode upon the activation of the supplypump 216, which increases the pressure of the supply flow 318. Theincreased pressure of the supply flow 318 provided by the supply pump216 is sufficient to overcome the preload force of the spring 314 andforce the poppet 312 to retract into the outer shell 310, thereby movingthe poppet 312 off of its seat on the nozzle opening 316 and permittingan injection flow 404 to pass through the nozzle opening 316. In someembodiments, the poppet 312 travels only between a fully closed positionand a fully open position. In other words, the poppet 312 is notconfigured to stop at any intermediate positions between the fullyclosed and fully open positions. This permits the lance injectorassembly 218 to precisely control the injection of reductant accordingto variables such as time and pressure rather than valve position.

At the same time as the injection flow 404 is expelled from the nozzleopenings 316, a portion of the reductant supplied to the lance injectorassembly 218 as supply flow 318 travels through the return passage 304as return flow 320 to cool the supply passage 302. For example, if thesupply pump 216 is operating between approximately 7.5 bar (i.e., 109psi) and 10 bar (i.e., 145 psi), the return flow 320 may range betweenapproximately 4 and 9 liters per hour. As the supply flow 318transitions from the supply passage 302 to the return passage 304 andbecomes the return flow 320, it may pass through a donut shaped orificeproximate the one or more nozzle openings 316. The donut-shaped orificemay generate a pressure drop, resulting in high pressure atomizationacross the nozzle openings 316.

Referring now to FIGS. 5-7, another example of a liquid only lanceinjector assembly 500 is depicted. Specifically, FIG. 5 depicts aperspective view of the lance injector assembly 500, while FIGS. 6 and 7depict cross-sectional views of the lance injector assembly 500. Thelance injector assembly 500 includes a hydraulically-actuated nozzleassembly 502 situated at the end of a shaft 504. The shaft 504 may bemounted to an exhaust conduit or pipe using a mounting system 506. Themounting system 506 may be coupled to a remote actuator 508 that isconfigured to activate the nozzle assembly or otherwise control a supplyof pressurized fluid to the hydraulically-actuated nozzle assembly 502.In various embodiments, the remote actuator 508 may be any suitable typeof electronic actuator.

A supply line 510 and cooling lines 512, 514 may be situated within theshaft 504 to supply reductant to the hydraulically-actuated nozzleassembly 502 and to cool the supply line 510 to prevent the formation ofdeposits. In some embodiments, the cooling lines 512, 514 are suppliedwith reductant. In other embodiments, the cooling lines 512, 514 aresupplied with a different coolant fluid (e.g., engine fluid,transmission fluid, air or any other onboard gas, refrigerant as acooling medium, etc.). The supply line 510 and cooling lines 512, 514may be located and retained within the shaft 504 through use of an outercap component 516. In some embodiments, a thermal barrier coating 518may be applied to the side of the shaft 504 facing the exhaust flow inorder to provide additional thermal protection to the assembly 500.

As depicted specifically in FIGS. 6 and 7, the mounting system 506 ofthe lance injector assembly 500 may be configured to prevent the remoteactuator 508 from directly contacting an exhaust pipe 602 on which thelance injector assembly 500 is mounted. Instead, the mounting system 506may include a spacer component 702, an inner cap component 704, andmounting ring members 706. In various embodiments, one or more of thecomponents 702-706 is fabricated from stainless steel. An insulatingregion 710 may be formed between the spacer component 702 and the outercap component 516 to prevent the transfer of heat from the exhaust pipe602 to the remote actuator 508. In various embodiments, the insulatingregion 710 may be filled with air, a vacuum, or an insulating material.

FIGS. 8-10 illustrate cross-sectional views of liquid only lanceinjector assemblies 800-1000 similar to the lance injector assembly 500depicted in FIGS. 5-7. For example, lance injector assemblies 800-1000may represent embodiments of the lance injector assembly 500 scaled formixers of various sizes. Referring now to FIG. 8, a lance injectorassembly 800 is depicted. The lance injector assembly 800 may beutilized, for example, with an exhaust pipe 802 having a diameter ofapproximately 13 inches. A remote actuator 804 is shown to be mounted onthe exterior of the exhaust pipe 802. A shaft 806 is coupled to theremote actuator 804 and extends into the interior of the exhaust pipe802 in order to expel reductant from a nozzle and actuation assembly808. In some embodiments, the distance 810 that the shaft 806 extendsinto the exhaust pipe 802 is approximately half the diameter of theexhaust pipe 802. In other words, the shaft 806 may extend to thecenterline of the exhaust pipe 802. Thus, for example, when the exhaustpipe has a diameter of 13 inches, the distance 810 is approximately 6.5inches.

The nozzle and actuation assembly 808 may be configured to emit a sprayof reductant having a substantially cone-like shape. In variousembodiments, the shape of the reductant spray emitted by the nozzle andactuation assembly 808 may have a first cone shape 812 or a second coneshape 814. The spray cone angle may be selected to best match thedimensions of the mixer and the exhaust pipe 802 while minimizing theamount of reductant coming into direct contact with the exhaust pipe802. In other embodiments, the nozzle and actuation assembly 808 mayemit a spray of reductant having any other desired geometry.

Referring now to FIG. 9, a lance injector assembly 900 is depicted. Thelance injector assembly 900 may be utilized, for example, with anexhaust pipe 902 having a diameter of approximately 10.5 inches. Aremote actuator 904 is shown to be mounted on the exterior of theexhaust pipe 902. A shaft 906 is coupled to the remote actuator 904 andextends into the interior of the exhaust pipe 902 to expel reductantfrom a nozzle and actuation assembly 908. Shaft 906 may extend to thecenterline of the exhaust pipe 902, a distance 910 of approximately 5.25inches. Similar to the nozzle and actuation assembly 808 of the lanceinjector assembly 800, the nozzle and actuation assembly 908 may beconfigured to emit reductant spray in a first cone shape 912 or a secondcone shape 914.

Turning now to FIG. 10, a lance injector assembly 1000 is depicted. Thelance injector assembly 1000 may be utilized with an exhaust pipe 1002having a diameter of approximately 5 inches. A remote actuator 1004 isshown to be mounted on the exterior of the exhaust pipe 1002. A shaft1006 is coupled to the remote actuator 1004 and extends into theinterior of the exhaust pipe 1002 to expel reductant from a nozzle andactuation assembly 1008. Shaft 1006 may extend to the centerline of theexhaust pipe 1002, or a distance 1010 of approximately 2.5 inches.Similar to the nozzle and actuation assemblies 808 and 908, the nozzleand actuation assembly 1008 may be configured to emit a reductant sprayin a first cone shape 1012 or a second cone shape 1014.

Referring now to FIGS. 11-23, various hydraulically-actuated nozzleassemblies are depicted. The nozzle and actuation assemblies depictedherein may be utilized with the lance injector assembly 500 as depictedin FIGS. 5-7. Each of the examples depicted in FIGS. 11-23 may beactuated without the use of any electronics located within the lanceportion (i.e., shaft 504) of the lance assembly 500. However, withsufficient cooling and insulation, electronic actuators (e.g., solenoidvalves, piezo-electric valves) may be utilized within the lance tocontrol a flow of reductant from the lance injector assembly 500.

Turning now to FIGS. 11 and 12, examples of hydraulic actuatorassemblies 1100 and 1200 for a liquid only lance are depicted. Actuatorassembly 1100 is shown to include an inner body 1102 and a nozzle body1104. In operation, a supply 1110 of reductant may pass through one ormore supply passages 1108 of the nozzle body 1104 toward a nozzle outlet1106. The nozzle outlet 1106 may be blocked by one or more valve members1112 that are nominally seated against the nozzle outlet 1106. Thepreload force to hold the valve members 1112 against the nozzle outlet1106 may be provided by a spring 1118 acting upon a needle shaped member1114 that contacts one or more of the valve member 1112. In someembodiments, the needle shaped member 1114 includes a shoulder portion1116, and the spring 1118 acts directly upon the shoulder portion 1116.

When the hydraulic actuator assembly 1100 is operating in arecirculation mode (i.e., the pressure of the supply 1110 isinsufficient to overcome the preload supplied by the spring 1118), thesupply 1110 of reductant may travel around the valve members 1112,through the needle shaped member 1114 and return to a reductant supplysource using a return passage 1120. When the hydraulic actuator assembly1100 is operating in an injection mode (i.e., the pressure of the supply1110 is sufficient to overcome the preload supplied by the spring 1118),the supply 1110 forces the valve members 1112 off their seated position,permitting a portion of the supply 1110 to exit the nozzle body 1104through the nozzle outlet 1106. The portion of the supply 1110 that doesnot exit the nozzle body 1104 may flow past the valve members 1112 andthe needle shaped member 1114 to exit to the reductant supply sourceusing a return passage 1122.

FIG. 12 depicts a hydraulic actuator assembly 1200 similar to thehydraulic actuator assembly 1100 in greater detail. As shown, a supply1210 of reductant may be provided to a nozzle body 1204 using one ormore supply passages 1208. A nozzle outlet 1206 may be blocked by one ormore valve members 1212 that are nominally seated against the nozzleoutlet 1206. A preload force 1218 to hold the valve members against thenozzle outlet 1206 may be provided by a preload member 1214. In someembodiments, the preload member 1214 includes a spring. When thepressure of the supply 1210 is sufficiently raised (i.e., by the remoteactuator 508) to overcome the preload force 1218, the supply 1210 forcesthe valve members 1212 away from their seated position blocking flowfrom the nozzle outlet 1206, permitting a portion of the supply 1210 toflow from the nozzle outlet 1206. A second portion 1216 of the reductantmay flow around the valve members 1212 to act directly upon the preloadmember 1214 in opposition to the preload force 1218.

Referring now to FIGS. 13 and 14, perspective and cross-sectional viewsof a full length hydraulic actuator assembly 1300 are respectivelyshown. Hydraulic actuator assembly 1300 is shown to include a main body1302 with an external threaded portion 1304. A nut 1308 may bethreadably coupled to the threaded portion 1304 in order to retain oneor more components of the actuator assembly 1300 within the main body1302. In other embodiments, nut 1308 may be coupled to main body 1302using a welding process. The main body 1302 is further shown to includemultiple passages 1306. Passages 1306 may be configured to house supplyand cooling lines (e.g., supply line 510, cooling lines 512, 514depicted in FIG. 5). Reductant flowing through the supply line may exitthe actuator assembly 1300 through an outer nozzle body 1310 and aroundor through a nozzle disc 1312. The nozzle disc 1312 may include anydesired geometry (e.g., number and pattern of orifices) to produce aflow of reductant from the lance assembly having a desired shape.

The interior of the hydraulic actuator assembly 1300 as depicted in FIG.14 is shown to include an inner nozzle body 1402 and a needle member1404. The needle member 1404 may nominally block a flow of reductantthrough the outer nozzle body 1310 and the nozzle disc 1312 due to theapplication of a preload force applied by a preload member 1406 and aspring 1408. When injection is desired, a pressurized supply 1410 flowsthrough the inner nozzle body 1402 and forces the needle member 1404 inopposition to the preload force (i.e., to the left, as depicted in FIG.14), permitting a portion of the supply 1410 to exit the assembly 1300.

Turning now to FIGS. 15 and 16, perspective and cross-sectional views ofa reduced length hydraulic actuator assembly 1500 are respectivelyshown. The reduced length assembly hydraulic actuator assembly 1500 mayprovide several advantages over the full length assembly 1300 depictedin FIGS. 13 and 14, namely a reduction in the size of the exhaust pipeopening required to install and mount the lance. Hydraulic actuatorassembly 1500 is shown to include a shaft portion 1502 coupled to a mainbody 1504. An integrated nut and outer nozzle body 1506 may bethreadably coupled to the main body 1504 to retain one or morecomponents of the actuator assembly 1500 within the main body 1504.Reductant supply through a supply line (not shown) disposed within theshaft 1502 may exit the actuator assembly 1500 through the integratednut and outer nozzle body 1506 and around or through a nozzle disc 1508.

The interior of the hydraulic actuator assembly 1500 as depicted in FIG.16 is shown to include a needle member 1606. The needle member 1606 maynominally block a flow of reductant through the nozzle body 1506 and thenozzle disc 1508 due to the application of a preload force applied by apreload member 1608 and a spring 1610. When injection is desired, apressurized supply 1604 flows from a supply passage 1602 and forces theneedle member 1606 in opposition to the preload force, permitting aportion of the supply 1604 to exit the assembly 1500.

FIG. 17 depicts a cross-sectional view of a direct actuation assembly1700. The direct actuation assembly 1700 includes a nozzle body 1702with a nozzle passage 1704. Control of a supply flow 1706 of reductantthrough the nozzle passage 1704 may be achieved through verticalmovement of a shaft assembly 1708. The shaft assembly 1708 may include ashaft member 1710 and a ball member 1712. When the ball member 1712 isflush against a seat orifice 1714, the supply flow 1706 may be blockedfrom travel through the nozzle passage 1704. However, when the ballmember 1712 is lifted from the seat orifice 1714 (e.g., throughoperation of a remote actuator such as remote actuator 508), the supplyflow 1706 may flow around the ball member 1712 and exit the lanceassembly through the nozzle passage.

FIGS. 18 and 19 illustrate cross-sectional views of a gate valveassembly 1800 in a closed position and an open position, respectively.The gate valve assembly 1800 is shown to include a shaft member 1802configured to travel in a vertical direction. When the gate valveassembly 1800 is in the closed position, the shaft member 1802 may restflush against a valve seat 1804. The shaft member 1802 is shown toinclude an interior fluid passage 1806 having a substantially U-shapedgeometry. In other embodiments, the interior fluid passage 1806 may haveany other desired geometry. In the closed position, as depicted in FIG.18, the interior fluid passage 1806 may be positioned such that theinterior fluid passage 1806 is out of alignment with both a supplypassage 1808 and a discharge passage 1810. However, when the shaftmember 1802 is lifted (e.g., through operation of a remote actuator) bya distance 1812 as depicted in FIG. 19, the interior fluid passage 1806may be moved into alignment with both the supply passage 1808 and adischarge passage 1810, and a supply of reductant 1814 may flow from thesupply passage 1808, through the interior fluid passage 1806, and outthrough the discharge passage 1810.

Turning now to FIG. 20, a cross-sectional view of a mechanical actuatorassembly 2000 is depicted. The mechanical actuator assembly 2000 isshown to include a nozzle body 2002 and a movable shaft component 2004with a supply passage 2006 for a supply flow 2008 of reductant. Thesupply flow 2008 may be nominally blocked from exiting a nozzle outlet2010 of the nozzle body 2002 by a valve member 2012. The valve member2012 may be retained in the nominal position by a preload member 2014.In some embodiments, the valve member 2012 is inseparably coupled to thepreload member 2014.

When injection flow from the assembly 2000 is desired, the movable shaftcomponent 2004 may travel vertically upwards (e.g., through operation ofa remote actuator) such that the preload member 2014 travels leftwardsinto the recess 2016 of the shaft component 2004. This relief of thepreload force against the valve member 2012 permits the supply flow 2008to travel past the valve member 2012 and exit the assembly 2000 throughthe nozzle outlet 2010. In some embodiments, some portion 2018 ofreductant not travelling through the nozzle outlet 2010 may flow pastthe preload member 2014 and return to a reductant supply source.

In some embodiments, liquid only lance injector assemblies may beconfigured to provide air insulation to reductant flowing through asupply line of the lance injector assembly such that liquid cooling isnot needed. Such lance injector assemblies do not have any coolantlines, for example, reductant return lines to provide cooling. Forexample, FIGS. 21 and 22 are various views of a liquid only lanceinjector assembly 2100, according to an embodiment. The lance injectorassembly 2100 includes a shaft 2104 configured to extend into an exhaustconduit of an aftertreatment system. The shaft 2104 is hollow anddefines a channel therethrough. The shaft 2104 may have an innerdiameter in a range of 0.5 inches to 1.5 inches (e.g., 0.5, 0.6, 0.7,0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 inches, inclusive). Air ispresent between the shaft 2104 and the supply line 2110 such that airinsulation is provided around the supply line 2110 which inhibits heattransfer from the shaft 2104 to the supply line 2110 and the reductantflowing therethrough.

A cap 2116 is disposed on and coupled to a first end of the shaft 2104.The cap 2116 may have a substantially solid structure. A supply line2110 extends through the cap 2116 and is disposed in the channel definedby the shaft 2104. The supply line 2110 extends beyond a second end ofthe shaft 2104 that is opposite the first end. A bend 2111 is defined inthe supply line 2110 proximate to a second end 2105 of the shaft 2104opposite the first end such that a portion of the supply line 2110 thatextends beyond the second end of the shaft 2104 and is configured to beexposed to a flow path of an exhaust gas is substantially perpendicularto an upstream portion of the supply line 2110. A dosing module 2114 isfluidly coupled to an upstream end of the supply line 2110 andconfigured to provide a reductant to the supply line 2110. An adapter2102 defining a nozzle is coupled to a downstream end of the supply line2110 located distal from the bend 2111 and is configured to insert astream, jet, or spray of the reductant into the exhaust gas. FIG. 22shows the lance injector assembly 2100 with a bottom portion of theshaft 2104 removed. As shown in FIG. 22, the supply line 2110 extendsthrough the shaft 2104 proximate to longitudinal axis of the shaft 2104.The downstream end of the supply line 2110 extends through a wall of theshaft 2104 such that the adapter 2102 is disposed outside the shaft2104.

As described above, the lance injector assembly 2100 and the other lanceinjector assemblies described with respect to FIGS. 23-32 do not includeDEF coolant lines. This reduces complexity of the assembly 2100, reducesmanufacturing cost, inhibits temperature increase in an upstreamreductant storage tank which may happen due to return of heatedreductant via reductant return lines, and removes problems with failureof lance injector assemblies due to reductant deposit formation inreductant return lines. Additionally, the lance injector assembly 2100and the other lance injector assemblies described with respect to FIGS.23-32 do not include a solid elbow and instead, include an empty aircavity to reduce the thermal mass and hence, improve thermalperformance. Moreover, cost is further reduced by excluding a checkvalve which beneficially also reduces thermal mass.

Referring to FIGS. 23-25, a liquid only lance injector assembly 2200 isshown, according to another embodiment. The liquid only lance injectorassembly 2200 includes a shaft 2204 configured to provide airinsulation, as previously described. A cap 2216 is disposed on andcoupled to a first end of the shaft 2204. The shaft 2204 may have aninner diameter Ds in a range of 1 inches to 2 inches (e.g., 1.0, 1.1,1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0 inches, inclusive). Thecap 2216 may have a substantially solid structure. A supply line 2210extends through the cap 2216 and is disposed in the channel defined bythe shaft 2204. A bend 2211 is defined in the supply line 2210 such thata portion of the supply line 2210 that is located proximate to adownstream end 2205 of the shaft 2204 that is located opposite the cap2216, is substantially perpendicular to an upstream portion of thesupply line 2210. An opening 2207 is defined in a wall of the shaft 2204proximate to a second end 2205 of the shaft 2204 that is opposite thefirst end. A nozzle 2203 is disposed at a downstream end of the supplyline 2210. The nozzle 2203 is coupled to the shaft 2204 around theopening 2207 such that reductant is able to flow from the nozzle 2203through the opening 2207 and into an exhaust gas flowing through theexhaust conduit.

In some embodiments, the nozzle 2203 is disposed on or defined by anadapter 2202 that is coupled to the downstream end of the supply line2110. The adapter 2202 may be coupled fluidly coupled to oralternatively, may extend through the opening 2207 defined in a wall ofthe shaft 2204. In some embodiments, the opening 2207 may be defined ata distance of about 1 inches to 2 inches from the downstream end 2205 ofthe shaft 2204 (e.g., between 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7,1.8, 1.9, or 2.0 inches, inclusive). As shown in FIG. 25, the adaptor2202 defines an aperture 2209 having a constant aperture diameter DAupstream of the nozzle 2203.

FIGS. 26 and 27 show a liquid only lance injector assembly 2300,according to another embodiment. The lance injector assembly 2300 issubstantially similar to the lance injector assembly 2200 and includessimilar components. However, different from the adapter 2202, the lanceinjector assembly 2300 includes an adapter 2302 fluidly coupled to adownstream end of the supply line 2210. The adapter 2302 defines anaperture 2309 upstream of the nozzle 2303. The aperture 2309 defines afirst diameter DN1 proximate to the supply line 2210 and a seconddiameter DN2 smaller than the first diameter DN1 distal from the supplyline 2210 (i.e., upstream of the nozzle 2303) such that the aperture2309 tapers inwardly from the supply line 2210 towards the nozzle 2303.The first diameter DN1 may correspond to an inner diameter of the supplyline 2210. The larger diameter upstream end of the adapter 2302 allowsreductant to transition from the supply line 2210 to the adapter 2302with minimal obstruction. This inhibits formation of reductant depositswhich can clog the aperture 2309 and/or the nozzle 2303.

FIG. 28 is a top, side perspective view of a liquid only lance injectorassembly 2400, according to an embodiment. In various embodiments, theelements or components of the lance injector assembly 2400 can be usedwith any of the lance injector assemblies described 2100, 2200, 2300.The liquid only lance injector assembly 2400 includes a hollow shaft2404 defining a channel, as previously described. In some embodiments,the shaft 2404 may have an inner diameter in a range of 1 inches to 2inches (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0inches, inclusive). A cap 2416 is coupled to an upstream end of theshaft 2404 and defines a central opening 2419. A supply line 2410extends into and is disposed in the channel defined by the shaft 2404through the cap 2416. Because of the central opening 2419, the supplyline 2410 does not contact the cap 2416 and heat transfer from the cap2416 to the supply line 2410 and therefore, the reductant flowingthrough the supply line 2410, is inhibited.

FIG. 29 is a top, side perspective view of a liquid only lance injectorassembly 2500, according to another embodiment. In various embodiments,the elements or components of the lance injector assembly 2500 can beused with any of the lance injector assemblies 2100, 2200, 2300. Theliquid only lance injector assembly 2500 includes a hollow shaft 2504defining a channel and configured to provide air insulation, aspreviously described. In some embodiments, the shaft 2504 may have aninner diameter in a range of 1 inches to 2 inches (e.g., 1.0, 1.1, 1.2,1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0 inches, inclusive). A cap 2516is coupled to an upstream end of the shaft 2504 and a supply line 2510extends through the cap 2516 into the shaft 2504 and is disposed in thechannel defined by the shaft 2504. The cap 2516 includes an annularportion 2517 and a central hub 2520 disposed circumferentially inwardsof the annular portion 2517 around a longitudinal axis of the cap 2516.The central hub 2520 is coupled to the annular portion 2517 via radialribs 2518 extending from an outer periphery of the central hub 2520 toan inner periphery of the annular portion 2517 such that gaps 2519 aredefined between adjacent radial ribs 2518. The supply line 2510 extendsthrough the central hub 2520 into the shaft 2504. The central hub 2520serves to support the supply line 2510 as well as position the supplyline 2510 substantially along a longitudinal axis of the shaft 2504.Since the annular portion 2517 is coupled to the central hub 2520 viaonly the radial ribs 2518, the ribs provide the only source ofconductive heat transfer from the annular portion 2517 to the centralhub 2520. Therefore heat transfer to the supply line 2510 is reducedrelative to a solid cap.

Referring to FIGS. 30-32, a liquid only lance injector assembly 2600 isshown, according to still another embodiment. In various embodiments,the elements or components of the lance injector assembly 28 can be usedwith any of the lance injector assemblies 2100, 2200, 2300. The liquidonly lance injector assembly 2600 includes a hollow shaft 2604 defininga channel configured to provide air insulation, as previously described.In some embodiments, the shaft 2604 may have an inner diameter in arange of 1 inches to 2 inches (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6,1.7, 1.8, 1.9, or 2.0 inches, inclusive) and a thickness in a range of0.5 mm to 1 mm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 mm, inclusive). Anopening 2607 is defined in a wall of a shaft 2604 at a distance in arange of 2 inches to 3 inches from a downstream or second end of shaft2604 (e.g., between 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or3.0 inches, inclusive). A nozzle or adapter defining the nozzle (e.g.,the adapter 2202, 2302) may be fluidly coupled to or alternatively, mayextend through the opening 2607. In some embodiments, an insulationlayer 2630 is disposed around the shaft 2604, to inhibit heat transferto the shaft 2604 and therefrom, the supply line 2610. Any suitableinsulation material can be used to form the insulation layer 2630 suchas, for example, fiber glass, textiles, polystyrene, etc.

A cap 2616 is coupled to a first or upstream end of the shaft 2604. Asupply line 2610 extends through the cap 2616 into the shaft 2604 and isdisposed in the channel defined by the shaft 2604. In some embodiments,the supply line 2610 may have an inner diameter in a range of 2.5 mm to3.5 mm (e.g., 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, or 3.5mm, inclusive) and a thickness in a range of 0.5 mm to 1.5 mm (e.g.,0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 mm, inclusive).An inner surface of the supply line 2610 may be electropolished. The cap2616 is substantially similar to the cap 2516, and includes an annularportion 2617 and a central hub 2620 with radial ribs 2618 extending fromthe hub 2620 to the annular portion 2617 such that gaps 2619 are definedbetween adjacent ribs. The supply line 2610 extends through the centralhub 2620 into the shaft 2604. The central hub 2620 serves to support thesupply line 2610 as well as position the supply line 2610 substantiallyalong a longitudinal axis of the shaft 2604. Different from the cap2516, an insulated bushing 2622 is positioned in the central hub 2620around the portion of the supply line 2610 disposed in the central hub2620 and is configured to inhibit heat transfer from the central hub2620 to the supply line 2610.

The liquid only lance injector assembly 2600 was subjected to variousrepetitions of a testing cycle that included 30 minutes of reductantdosing, 5 minutes without reductant dosing, and then 30 minutes ofreductant dosing (30-5-30 cycle). The various testing conditions thatthe lance injector assembly 2600 was tested at are listed in Table 1:

TABLE 1 Lance injector assembly testing conditions Exhaust Gas ExhaustGas Reductant Flow Rate Temperature Flow Rate Test Condition (kg/min)(Celsius) (ml/sec) Test Condition 1 10.5 210 0.23 Test Condition 2 11.1290 0.275 Test Condition 3 18.3 345 0.59 Test Condition 4 33.6 470 0.91

The measure of success for each test was that temperature of thereductant emitted from the lance injector assembly 2600 remained lessthan 70 degrees Celsius and the reductant did not clog the supply line2610. The lance injector assembly 2600 passed multiple 30-5-30 cyclesfor each of the test conditions. The lance injector assembly 2600 evenpassed non-standard tests in which reductant is passed through thesupply line at 0.03 ml/second at test condition 4 for 2 hours, at 0.09ml/second at 550 degrees Celsius exhaust gas temperature for more than 1hours, and at exhaust gas temperature of 550 degrees Celsius withoutdosing, and then dosing reductant at test condition 1, 2, 3, or 4. Thisindicates that the air insulation provided by the liquid only lanceinjector assembly 2600 significantly inhibits heat transfer from theshaft 2604 to the supply line 2610 and thereby, the reductant flowingtherethrough. Thus, the lance injector assembly 2600 can inhibitreductant from decomposing within the supply line 2610 even at very highoperating temperatures of the exhaust gas as well as inhibit reductantdeposit formation, thereby increasing the operational life of the lanceinjector assembly 2600.

IV. Construction of Example Embodiments

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of what may beclaimed but rather as descriptions of features specific to particularimplementations. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described as actingin certain combinations and even initially claimed as such, one or morefeatures from a claimed combination can, in some cases, be excised fromthe combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

As utilized herein, the terms “substantially,” generally,” and similarterms are intended to have a broad meaning in harmony with the commonand accepted usage by those of ordinary skill in the art to which thesubject matter of this disclosure pertains. It should be understood bythose of skill in the art who review this disclosure that these termsare intended to allow a description of certain features described andclaimed without restricting the scope of these features to the precisenumerical ranges provided. Accordingly, these terms should beinterpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

The terms “coupled,” “attached,” “fastened,” “fixed,” and the like, asused herein, mean the joining of two components directly or indirectlyto one another. Such joining may be stationary (e.g., permanent) ormoveable (e.g., removable or releasable). Such joining may be achievedwith the two components or the two components and any additionalintermediate components being integrally formed as a single unitary bodywith one another, with the two components, or with the two componentsand any additional intermediate components being attached to oneanother.

The terms “fluidly coupled,” “fluidly communicable with,” and the like,as used herein, mean the two components or objects have a pathway formedbetween the two components or objects in which a fluid, such as air,liquid reductant, gaseous reductant, aqueous reductant, gaseous ammonia,etc., may flow, either with or without intervening components orobjects. Examples of fluid couplings or configurations for enablingfluid communication may include piping, channels, or any other suitablecomponents for enabling the flow of a fluid from one component or objectto another.

It is important to note that the construction and arrangement of thesystem shown in the various example implementations is illustrative onlyand not restrictive in character. All changes and modifications thatcome within the spirit and/or scope of the described implementations aredesired to be protected. It should be understood that some features maynot be necessary, and implementations lacking the various features maybe contemplated as within the scope of the application, the scope beingdefined by the claims that follow. When the language “a portion” isused, the item can include a portion and/or the entire item unlessspecifically stated to the contrary.

1.-20. (canceled)
 21. A lance injector assembly for an exhaustcomponent, comprising: a shaft configured to extend into an exhaustconduit of the exhaust component, the shaft being hollow so as to definea channel therethrough, wherein an opening is defined in a wall of theshaft proximate to a second end of the shaft that is opposite the firstend; a cap coupled to a first end of the shaft; and a supply linedisposed within the channel defined by the shaft, wherein a nozzle isdisposed at a downstream end of the supply line, the nozzle beingfluidly coupled to the shaft around the opening such that reductant isable to flow from the nozzle through the opening and into an exhaust gasflowing through the exhaust conduit, wherein air is present in the spacebetween the supply line and the wall of the shaft, the air inhibitingheat transfer to the supply line.
 22. The lance injector assembly ofclaim 21, further comprising: an adapter coupled to the downstream endof the supply line, the adapter defining an aperture therethrough, thenozzle being disposed on or defined by a downstream end of the aperture,wherein the aperture has a first diameter proximate to the supply lineand a second diameter smaller than the first diameter distal from thesupply line such that the aperture tapers inwardly from the supply linetowards the nozzle.
 23. The lance injector assembly of claim 21, whereinthe cap comprises: an annular portion; a central hub disposedcircumferentially inwards of the annular portion around a longitudinalaxis of the cap; and a plurality of radial ribs extending from an outerperiphery of the central hub to an inner periphery of the annularportion and coupled to the annular portion such that gaps are definedbetween adjacent ribs of the plurality of ribs, wherein the supply lineextends through the central hub into the shaft.
 24. The lance injectorassembly of claim 23, wherein the cap further comprises: an insulatingbushing disposed in the central hub around a portion of the supply linethat us disposed in the central hub, the insulating bush configured toinhibit heat transfer to the supply line from the central hub.
 25. Thelance injector assembly of claim 21, further comprising: an insulatinglayer disposed around the shaft.
 26. The lance injector assembly ofclaim 21, further comprising: an adapter protruding outwardly from theopening, the nozzle being included in the adapter.